Method and composition for modifying soil and dust control

ABSTRACT

A composition for chemical improvement of soil and road base materials including an aqueous solution of a water repellant and an aqueous emulsion of a soil stabilizer and dust retardant is herein disclosed.

I. CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 12/729,683, filedMar. 23, 2010, which claims priority to Provisional Patent ApplicationNo. 61/165,235 filed Mar. 31, 2009, Provisional Patent Application No.61/169,041 filed Apr. 14, 2009, and Provisional Patent Application No.61/309,223 filed Mar. 1, 2010, all of which are incorporated herein byreference.

II. BACKGROUND OF THE INVENTION

A. Field of Invention

This invention generally relates to methods and compositions forimproving the strength and longevity of secondary roadways throughenvironmentally sound practices; specifically, improved dustsuppression, soil stabilization, and water repellency.

B. Description of the Related Art

The engineering and construction of secondary roads (hereafter, “gravelroads,” “earth roads,” or “unpaved roads”) has been perpetually plaguedby two interrelated problems: the deterioration of the road due towater, and the loss of surface cohesion and road compaction due totraffic. The deleterious effects of water on roadways, in particular,are well documented in the prior art. In cold weather, moisture thatpenetrates a road's base layers freezes and rips cracks into the roadsubstrate that seriously undermine the load bearing capacity andlongevity of the roadway. Likewise, in milder weather, when water seepsinto the road's base layers it results in softening and erosion thatcauses potholes that are an expensive and recurring problem. And if thepotholes are not immediately repaired, they fill with water and furtherexacerbate the deterioration of the roadway.

The impact of water on secondary roads—such as rural roads, accessroads, field and forestry roads, or mountain roads—is especiallypronounced because the quality of the surfacing materials is lower thanin an asphalt paved road, for example, and thus provides reduced surfaceprotection from the elements. Additionally, because of capillary action,water also seeps into the road base from the sides and bottom of theroad's base or sub-base. Compared to sealed or “paved” roads, whichrequire large machinery to pour concrete or to lay and smooth abitumen-based surface, secondary unpaved roads are relatively easy andinexpensive to build. But unpaved roads require much more frequentmaintenance—particularly after wet periods or when faced with increasedtraffic—and are generally prone to other problems not associated withpaved roads.

For example, many secondary roads—of either an earth or gravelvariety—utilize native soils, often in conjunction with gravel quarriedfrom local resources, to create the road's sub-base and base layers.Unfortunately, native soils and gravel are not always of suitablequality, resulting in a road base with diminished physical andmechanical properties. When secondary roads are constructed of poor roadbase materials, routine maintenance is not strictly employed, and theroad is exposed to heavy moisture and/or traffic, the erosion of theroad—due to damage to the road surface, sub-base, and base materials—ishastened.

Defects in road surfaces are typically classified into two categories:surface deterioration and surface deformation. While surfacedeterioration is related mostly to the quality of the surfacingmaterials and the way they respond to weather or traffic stresses,surface deformations often have combined causes that include bothstresses to the road surface itself and other factors such as sub-baseand base capacity and stability.

Surface deterioration is exemplified by “dust,” the result of loss offine binder material from road surfaces. Dust is a substantial problemfor secondary roads, as the loss of these fine materials leads to othertypes of road distress such as loss of cohesion and compaction of theroad fill material, and reduced capacity to maintain the requisitemoisture in the road fill.

Surface deformations include ruts, corrugations, depressions, andpotholes. Ruts are longitudinal depressions in the wheel paths caused byhigh moisture content, inadequate strength in the subsurface soil orbase, inadequate surface course thickness, or heavy traffic loads.Corrugating or “washboarding” is a series of ridges and depressionsacross the road surface caused by lack of surface cohesion. Depressionsare localized low areas one or more inches below the surrounding roadsurfaces that are caused by settlement, excessive moisture content,and/or improper drainage. Potholes are small depressions or voids in theroad surface one or more inches deep which are caused by excessivemoisture content, poor drainage, weak sub-base or base, poorly gradedaggregate, or a combination of these factors.

As such, the problems typically associated with secondary roads—bothsurface deterioration and defoiination—are caused by: 1) the harmfuleffects of water and high moisture content, including settlement anderosion, on the road surface and base, 2) the lack of surface cohesionand resulting loss of road compaction caused by dust, and 3) the heavytraffic loads exerted on roads with weak or inadequate soil, sub-base,or base.

Industry has provided for the addition of various chemical additives toimpart water repellency on road materials, with varying degrees ofsuccess and environmental impact. However, water repellant chemicals arenot binders, and load bearing capacity and stability are not improved bytheir application to the soil or road base. In many cases, dust can alsobe reduced on gravel roads by applying chemical additives (commonlyknown in the art as “dust suppressors” or “dust retardants”) which drawmoisture from the air to improve fine aggregate cohesion. And “soilstabilizers,” which are chemicals designed to act as binders andcoalesce forming bonds between the soil or aggregate particles, haveshown promise in greatly improving the load bearing and traffic capacityof the road. But existing soil stabilizers and dust retardants aredifficult to apply and use in cold climates, tend to have long curetimes, short life-cycles, and do not provide the requisite protectionagainst water damage; particularly excessive moisture content resultingfrom capillary action.

Therefore, a single chemical composition capable of resisting theaforementioned problems—by providing water repellency for reducedmoisture content, dust retardant for improved surface cohesion, and soilstabilizers for improved load bearing and traffic capacity—would be ofgreat utility in the field of art; particularly if the chemicalcomposition could be applied in an economical and environmentally soundmanner. Although road builders have long employed soil additives as amechanism for preventing and avoiding surface deteriorations anddeformations, formulating a combination of chemicals and a methodologyfor applying the chemical additives in a cost-effective manner hasproved elusive. Specifically, although various chemicals have beenprovided for binding road base materials together for improved strengthand load bearing capacity and for repelling water from the road surface,previous efforts have thus far failed to provide an environmentallyappropriate solution to the secondary road erosion and maintenanceissues that have long plagued the art. Thus, there is a need in the artfor improved compositions that provide extraordinary increases in loadbearing capacity, outstanding dust retardant capabilities, superiorwater repellant properties, and can be administered in a singleapplication phase. Such an improved composition could provide anengineered stabilized water repellant road base and surface topping forearth or gravel roads; or, it could prepare a road sub-base or base forchip sealing, paving, or milling applications.

Repairing damaged roadways by conventional methods can be extremelyexpensive, time consuming, and environmentally disruptive because theentire compacted gravel layer of the road must be replaced. Excavatingthe roadbed of a 1-km portion of road measuring 4 m in width producesabout 2000 cubic meters (m³) of earthy waste; in a conventional road bedrepair project, this would require roughly 220 truckloads of waste to beremoved from the worksite, with 220 truckloads of new gravel beingshipped back the worksite to complete the project. In isolatedlocations, or locations with difficult terrain, the expense of removingand late: replacing the gravel is exorbitant—as is the impact on localresidents (who must cope with noise and air pollution), normal users ofthe roadway (who experience detours or extended delays during repair),and the landfills that store the removed waste.

As a result, there is a need in the art for a single phase chemicaltreatment method that incorporates soil stabilization, dust retardant,and water repellant chemicals into native soils. With such a singlephase treatment option, road builders will be able improve the longevityof the roadway, impart increased load bearing and traffic capacity, andreduce the time, costs, and environmental impact associated withconventional road repair projects.

III. BRIEF DESCRIPTION OF THE DRAWINGS

At least one embodiment of the invention is set forth in the followingdescription and is shown in the drawings and is particularly anddistinctly pointed out and set forth in the appended claims.

FIG. 1 shows a pulvimixer;

FIG. 2 shows a side view of the pulvimixer, wherein the soil or roadbase materials are being pulverized, sprayed, and mixed with thechemical composition of the present invention.

FIG. 3 shows a perspective view of the pulvimixer;

FIG. 4 shows a graph showing additive impact on dry strength;

FIG. 5 shows a graph showing dry strength; and,

FIG. 6 shows a graph showing wet strength.

IV. SUMMARY

Accordingly, several objects and advantages of the present invention arethe provision of a single chemical soil or road base materialimprovement composition that imparts extraordinary dust control, soilstabilization, and water repellency properties onto native soils orother road base materials.

Additionally, the present invention provides a method for a singleapplication phase treatment of soil or road base materials characterizedby reduced cure time, decreased road construction time, reducedenvironmental impact (by virtue of reduced construction waste andtraffic), a wider range of effective use temperatures, a long lifecycle, and a stronger more dust resistant roadway.

Other benefits and advantages will become apparent to those skilled inthe art to which it pertains upon reading and understanding of thefollowing detailed specification.

V. DETAILED DESCRIPTION

In one embodiment of the present invention, a composition for improvingthe properties of soil or other road base materials is provided.Specifically, a blended mixture of the chemical composition detailedbelow is capable of improving the dust retardant, water repellant, andsoil stabilization properties of soil or other road base materials.Incorporating the chemical improvement composition into soil, or otherroad base materials, and then compacting, provides superior resistanceto surface deformations and deterioration by increasing the load-bearingstrength—in some cases, as much as 500%—of the roadway, greatly reducingdust caused by traffic or weather, and eliminating capillary wateruptake that results in moisture damage to the road. This invention is animprovement over traditional methods because it provides a compositionthat can be applied in a single application phase, under a wide range ofambient temperatures and conditions, to resolve all of the aboveproblems in the field of art.

The composition for chemical improvement of soil or road base materialsis comprised of an aqueous solution of a water repellant in combinationwith an aqueous emulsion of a soil stabilizer and dust retardant. In oneembodiment of the present invention, the characteristics of thecomposition for chemical improvement of soil or road base materials caninclude an aqueous solution of a water repellant that comprises about1.0% to about 5.0% by weight (including, but not limited to, 1, 2, 3, 4,and 5) of potassium hydroxide; about 10.0% to about 30.0% by weight(including, but not limited to, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19,20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30) of potassiummethylsiliconate; and about 65.0% to about 89.0% by weight (including,but not limited to, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77,78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, and 89) of water. In yetanother embodiment of the invention, instead of the aforementionedpotassium methylsiliconate, the aqueous solution of a water repellantcomprises about 10.0% to about 30.0% by weight (including, but notlimited to, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24,25, 26, 27, 28, 29, and 30) of sodium methylsiliconate.

In one embodiment of the present invention, the characteristics of thecomposition for chemical improvement of soil or road base materials caninclude a dust suppression and/or soil stabilization composition that isan aqueous emulsion comprising about 5.0% to about 60.0% by weight(including, but not limited to, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15,16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33,34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51,52, 53, 54, 55, 56, 57, 58, 59 and 60) of polyacrylic acid and polyvinylacetate and 40.0% to about 95.0% by weight (including, but not limitedto, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56,57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74,75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, and 90) ofwater. It is to be understood that this embodiment could consist ofstraight acrylic, straight polyvinyl acetate or an SBR (styrenebutadiene rubber), all in blends, copolymers, or homopolymers.

In another embodiment of the invention, the composition for chemicalimprovement of soil or road base materials can comprise about 2.5% toabout 30.0% by weight (including, but not limited to, 2.5, 2.6, 2.7,2.8, 2.9, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19,20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30) of polyacrylic acid andpolyvinyl acetate polymer; about 0.5% to about 2.5% by weight(including, but not limited to, 0.5, 0.6, 0.7, 0.8, 0.9, 1.1, 1.2, 1.3,1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, and 2.5) ofpotassium hydroxide; about 5.0% to about 15.0% by weight (including, butnot limited to, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, and 15) of potassiummethylsiliconate; and about 52.5% to about 92.0% by weight (including,but not limited to, 52.5, 52.6, 52.7, 52.8, 52.9, 53, 54, 55, 56, 57,58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75,76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, and 92)of water.

In yet another embodiment of the invention, the composition for chemicalimprovement of soil or road base materials can comprise about 3.75% toabout 45.0% by weight (including, but not limited to, 3.75, 3.76, 3.77,3.78, 3.79, 3.8, 3.9, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35,36, 37, 38, 39, 40, 41, 42, 43, 44, and 45) of polyacrylic acid andpolyvinyl acetate polymer; about 0.25% to about 1.25% by weight(including, but not limited to, 0.25, 0.26, 0.27, 0.28, 0.29, 0.3, 0.4,0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.20, 1.21, 1.22, 1.23, 1.24, and1.25) of potassium hydroxide; about 2.5% to about 7.5% by weight(including, but not limited to, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 4, 5, 6, 7,7.1, 7.2, 7.3, 7.4, and 7.5) of potassium methylsiliconate; and about46.25% to about 93.5% by weight (including, but not limited to, 46.25,46.26, 46.27, 46.28, 46.29, 46.3, 46.4, 46.5, 46.6, 46.7, 46.8, 46.9,47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64,65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82,83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93.0, 93.1, 93.2, 93.3, 93.4,and 93.5) of water.

In still another embodiment of the invention, the composition forchemical improvement of soil or road base materials can comprise about1.25% to about 15.0% by weight (including, but not limited to, 1.25,1.26, 1.27, 1.28, 1.29, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 3, 4, 5,6, 7, 8, 9, 10, 11, 12, 13, 14, and 15) of polyacrylic acid andpolyvinyl acetate polymer; about 0.75% to about 3.75% by weight(including, but not limited to, 0.75, 0.76, 0.77, 0.78, 0.79, 0.8, 0.9,1, 2, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.70, 3.71, 3.72, 3.73, 3.74, and3.75) of potassium hydroxide; about 7.5% to about 22.5% by weight(including, but not limited to, 7.5, 7.6, 7.7, 7.8, 7.9, 8, 9, 10, 11,12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22.0, 22.1, 22.2, 22.3, 22.4,and 22.5) of potassium methylsiliconate; and about 58.75% to about 90.5%by weight (including, but not limited to, 58.75, 58.76, 58.77, 58.78,58.79, 58.8, 58.9, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71,72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89,90.0, 90.1, 90.2, 90.3, 90.4, and 90.5) of water. It is to be understoodthat this embodiment could comprise mixtures, copolymers, orhomopolymers of acrylics, polyvinyl acetates, styrene butadiene rubbers,and styrene acrylics.

In still other embodiments of the present invention, the dustsuppression and/or soil stabilization portion of the composition canalso include an emulsifier. Furthermore, in certain embodiments of theinvention, the polyacrylic acid and/or polyvinyl acetate can comprise amixture of homopolymers, or can comprise one or more copolymers. Someembodiments may include styrene butadiene rubber and relatedcompositions, copolymers, and/or derivatives thereof. The chemicalcompositions described above are manufactured using conventionalmanufacturing equipment. Conventional mixers, emulsifiers, or colloidmills are utilized to blend these components into stable heterogeneousmixers or emulsions.

According to embodiments where the polyacrylic acid and/or polyvinylacetate components comprise homopolymers, the homopolymer components canbe present in ratios from about 1:1 to about 1:10,000 by mass ofpolyacrylic acid to polyvinyl acetate; or, from about 1:1 to about1:10,000 by mass of polyvinyl acetate to polyacrylic acid.

According to embodiments where the polyacrylic acid and/or polyvinylacetate components comprise one or more copolymers, the copolymers cancomprise random copolymers, block copolymers, graft copolymers and thelike or any combination thereof. Furthermore, the ratio of acrylic acidunits to vinyl acetate units within a copolymer can comprise from about1:1 to about 1:10,000 by mass of acrylic acid units to vinyl acetateunits; or, from about 1:1 to about 1:10,000 by mass of vinyl acetateunits to acrylic acid units.

Regardless of whether the embodiment comprises homopolymers and/orcopolymers, each polymer component can be present in a wide variety ofmolecular weights and polydispersities thereof. For instance, suitablemolecular weight ranges can comprise from about 10³ to about 10⁴ g/mol,from about 10⁴ to about 10⁵ g/mol, from about 10⁵ to about 10⁶ g/mol,from about 10⁶ to about 10⁷ g/mol, from about 10⁷ to about 10⁸ g/mol,from about 10⁸ to about 10⁹ g/mol, or even from about 10⁹ to about 10¹⁰g/mol. Here, as elsewhere in the specification and claims, ranges may becombined. Furthermore, the foregoing molecular weight ranges can becalculated according to any method known in the art including, withoutlimitation, weight average molecular weight and number average molecularweight. One of skill in the art will recognize that the numerical valueof a polymer molecular weight differs according to the calculationmethod.

A composition according to the aforementioned embodiments can comprise adust suppression, soil stabilization, and/or water repellant compositionthat can, for instance, be applied to unpaved road surfaces (eithersoil, earth, dirt, gravel, or other conventional aggregate substances).Such compositions may decrease the amount of dust caused by wind erosionor generated by vehicles operating on the unpaved surface. Otherembodiments can alternatively or additionally comprise a soilstabilization composition that increases the California Bearing Ratio(CBR value) and R-value of the soil or road base. In still otherembodiments, the composition can alternatively or additionally comprisea water repellant component that eliminates, or greatly reduces,capillary water uptake into road surfaces, bases, and sub-bases.Accordingly, such compositions can increase the weight-bearing capacityof an unpaved road surface, prevent erosion thereof, prevent wateruptake thereof, or otherwise enhance the mechanical characteristics ofthe soil to which it is applied.

In several embodiments of the present invention, methods for improvingsoil or road base materials are provided. In one embodiment, aheterogeneous mixture of an aqueous solution of a water repellant andaqueous emulsion of a soil stabilizer and dust retardant—according tothe various chemical embodiments described above—is provided and appliedto soil or road base materials (thereafter, “treated soil or road basematerials”). As used in this patent application, the term “soil” isbroadly used to describe the top layer of the earth's surface,consisting of rock and mineral particles mixed with organic matter (alsoknown as, by non-limiting reference, earth or dirt); whether originallylocated at the road construction site (“native soil” or “in situ soil”)or transported to the road construction site. As used in this patentapplication, the phrase “road base materials” is broadly used todescribe any substance from which a road surface, base, or sub-basecould be constructed; including, but certainly not limited to by thisnon-limiting reference, rock, broken rock, gravel (whether pebble,granule, or other size or mixture), sand, cobble, slag, or otherconstruction aggregate or fill material. In these embodiments, thematerial being treated is graded prior to application. Soil high inorganic matter, because it is not cohesive, creates some difficultiesestablishing the reaction necessary to render the soil hydrophobic. Themanner of composition application can include any method chosen withsound engineering judgment; but in most instances, application of thechemical agent to the soil is accomplished by the use of conventionalspray equipment (spray trucks). The agent is gravity fed or pumpedthrough hoses, spray nozzles, or fixed sprayers and evenly applied tothe soil or material to be treated.

In some embodiments of the invention, the soil or road base materialsare scarified (ripped open)—in this embodiment, to a depth of about 4-6inches (10.16 cm-15.24 cm)—by conventional road construction graders(particularly graders with rake attachments) prior to application of thesoil or road base material chemical improvement composition. This hasthe effect of allowing the composition to penetrate and permeate thesoil or road base material to a greater degree. Once applied, thecomposition penetrates into the soil or road base materials whereparticle weighting and loading mechanisms achieved through the processesof adsorption, prompt adherence of molecules to the surface of particlesand absorption and penetration of the substance into the inner structureof the particles. The water repellant portion of the composition reactswith minerals in the soil or road base materials and rapidly forms ahydrophobic silicone resin network that does not close pores in thesubstances, but rather permits the road to “breathe” in spite of waterrepellant properties. During the inventive process, evaporation of wateroccurs. The polymers of the aqueous acrylic polymer emulsion coalesceand form an intimate bond with the soil upon evaporation of the water.The sodium silicate and potassium silicate in water uses cohesion of thesoil particles to form discrete hydrophobic silicone networks.

In one embodiment of the invention, the treated soil or road basematerials are graded and compacted, using any means chosen with soundengineering judgment, and a top coat of the composition is applied.Motor-graders, asphalt grinders, mixers, pug mills, compactors, rollers,and other conventional construction equipment may be utilized to blend,set grade, and compact stabilized base, if necessary, as described inherein. A top coat is defined broadly as any application of the soil orroad base materials chemical improvement composition that is appliedafter compaction.

In one embodiment, penetration is dramatically improved by mechanicallymixing the chemical composition into soil or road base materials duringthe application step. The mechanical mixing process can include, but isnot limited to, the use of a specialized machine called a “pulvimixer”(The pulvimixer consists of an engine which directly drives a toothedrotor, whose teeth are replaced when they are damaged. In oneembodiment, the rotor is horizontal and turns at a rate of 100 to 200rpm in the opposite direction to the machine's direction of travel anddigs into the soil to depth of 500 mm, mixing the binder (enhancedpolymers) thoroughly with the clays or silts that make up the soil. Thistechnique allows soils to be exploited structurally). The pulvimixermechanically mixes the composition with the soil or road base materialsby simultaneously: 1) scarifying the soil or road base materials, whichwhen accomplished by a pulvimixer can additionally include breaking up(pulverizing) large pieces of stone or road topping in a mixing chamber;(2) applying the chemical improvement composition; (3) thoroughly mixingthe chemical improvement composition with the pulverized soil or roadbase material; and (4) grading the treated soil or road base material.This single application phase method prepares the treated soil or roadbase material—which is now a thoroughly mixed, homogeneous, well-gradedroadbed—for leveling and compaction. In some embodiments of theinvention, a top coat is then applied to the mechanically mixed andcompacted soil or road base materials. In other embodiments, a surfacecourse is applied to the compacted soil or road base materials prior toapplication of the top coat. A surface course can include anycombination of road surface materials used in the art; including, butnot limited to, asphalt concrete and bituminous surface treatments suchas chip seal.

Effective application amounts of some embodiments can comprise fromabout 1 liter per cubic meter of soil (i.e. 1 L/m³) to about 10 L/m³,from about 10 L/m³ to about 20 L/m³, from about 20 L/m³ to about 30L/m³, from about 30 L/m³ to about 40 L/m³, from about 40 L/m³ to about50 L/m³, from about 50 L/m³ to about 60 L/m³, from about 60 L/m³ toabout 70 L/m³, from about 70 L/m³ to about 80 L/m³, from about 80 L/m³to about 90 L/m³, from about 90 L/m³ to about 100 L/m³, or even greaterthan 100 L/m³.

The proper application of the chemical compositions for improvement ofsoil or road base materials of the present invention, particularly usingthe methodologies described above, greatly improves the load bearingstrength of unpaved roads, makes them virtually resistant to thedamaging effects of capillary water uptake and water erosion, andprovides superior dust retardant properties—under a wider range ofeffective application and use temperatures—than any composition in theprior art. Moreover, the chemical compositions described and claimedherein can be applied in a single phase to native soils, and due toreduced cure times the result is decreased road construction time,reduced environmental impact (by virtue of reduced construction wasteand traffic), and a longer life cycle.

With reference now to FIGS. 4-6, standard lab mix of well gradedlimestone was used to prepare all unconfined compressive strength (UCS)cores. All samples were prepared using standard lab practices for makingUCS cores. All samples were dried at 104° F. (219° C.) for 48 hours. DryUCS cores were broken after six hours at room temperature. Wet UCS coreswere broken after 48 hour soak in room temperature tap water,immediately after removal from water bath. Standard UCS cores aretypically three inches (7.62 cm) in diameter and compacted to a fourinch (10.16 cm) depth. Application rates of polymer (PBs) are based onsurface area. In these embodiments, Water Armour™ (a sodium silicate andpotassium silicate in water) was applied at a rate of 8 L/m³ on allsamples. In FIG. 4 the graph shows the impact of the addition of each ofthe additives, alone and together, on the UCS strength of standardlimestone. The Water Armour™ alone has a negative impact on the strengthof the cohesive limestone mix. The addition of polymer alone and polymerand Water Armour™ substantially increase the UCS values.

In FIG. 5, the graph shows that the addition of Water Armour™ to thepolymer has a negligible impact on the strength of the polymer/limestonemix alone. In FIG. 6, the graph shows that the addition of Water Armour™has a positive impact on the wet strength of the polymer/limestone mix.Testing shows at least a 17% increase in wet strength. Below is a tableshowing the results of the tests on the graphs.

TABLE 1 Dry SS/WA Wet SS/WA 1 gallon/ 1 gallon/ 1 gallon/ 1 gallon/ 1gallon/ 1 gallon/ 10 ft² 50 ft² 100 ft² 10 ft² 50 ft² 100 ft² 7965 25841559 2044 378 358 7672 2391 1817 2044 436 384 6122 1445 2498 573 356Avg.: 7253 2488 1607 2195 462 366 SS—Soil Sement ® (an aqueous acrylicvinyl acetate polymer emulsion WA—Water Armour ™

TABLE 2 Dry SS 40% so Wet SS 40% so 1 gallon/ 1 gallon/ 1 gallon/ 1gallon/ 1 gallon/ 1 gallon/ 10 ft² 50 ft² 100 ft² 10 ft² 50 ft² 100 ft²8282 2019 1557 1090 444 258 7886 1835 1575 639 370 234 8363 2179 1666709 318 278 7738 2143 1941 725 460 210 6920 1965 1652 907 315 323 Avg.:7838 2028 1678 814 381 261

Along with the testing shown in Tables 1 and 2, a control of water onlywas also run at 1 gallon per 10 square feet, with a result of 1050.Also, a control of 8 L of Water Armour™ was also run with a result of166.

In one example, aqueous acrylic vinyl acetate polymer emulsion was mixedand blended with the soil. A container had 3200 gallons (12,113 liters)of the emulsion diluted to 11 to 1 with water. The scarified road wasvery dry through the entire 6-8 inch (15.24 cm-20.32 cm) depth. Theemulsion soaked into the material. Another coat was applied, whichsoaked in even slower. The following day, the first section of lookedgood. The ruts were almost not visible. A total of 550 gallons (2082liters) had been applied to this first section, which was the 40% solidssection. A second section was the 50% solids section, which was also 250m×4.5 m. This section had 605 gallons (2290 liters) applied at 50%.

On the second day, sections 1 and 2 looked good after light traffic.Both sections appeared still at least damp, but held firm. A thirdsection would have both the emulsion and Water Armour™ applied. Thissection was 100 m×4.5 m and was 6 inches (15.24 cm) deep. Approximately100 gallons (376 liters) of Water Armour™ was mixed with 275 gallons(1041 liters) of the emulsion and filled the rest of the 3200 gallon(12,113 liters) tank with water. This was applied to the material. Whenit was dry a second coat was applied. Material was very tight and had aneven, white sheen.

The embodiments have been described, hereinabove. It will be apparent tothose skilled in the art that the above methods and apparatuses mayincorporate changes and modifications without departing from the generalscope of this invention. It is intended to include all suchmodifications and alterations insofar as they come within the scope ofthe appended claims or the equivalents thereof. Although the descriptionabove contains much specificity, this should not be construed aslimiting the scope of the invention, but as merely providingillustrations of some of the present embodiments of this invention.Various other embodiments and ramifications are possible within itsscope.

Furthermore, notwithstanding that the numerical ranges and parameterssetting forth the broad scope of the invention are approximations, thenumerical values set forth in the specific examples are reported asprecisely as possible. Any numerical value, however, inherently containcertain errors necessarily resulting from the standard deviation foundin their respective testing measurements.

Having thus described the invention, it is now claimed:

1. A composition for chemical improvement of soil and road basematerials, the composition comprising: an aqueous solution of a waterrepellant comprising about 0.25% to about 5.0% by weight of potassiumhydroxide; and, an aqueous emulsion of a soil stabilizer and dustretardant, wherein the aqueous solution and aqueous emulsion havepolymer components, wherein the polymer components have a molecularweight range of about 10⁴ g/mol to about 10¹⁰ g/mol.
 2. The compositionof claim 1, wherein the water repellant further comprises about 10.0% toabout 30.0% by weight of a methylsiliconate chosen from the groupcomprising potassium methylsiliconate and sodium methylsiliconate. 3.The composition of claim 2, wherein water repellant further comprisesabout 65.0% to about 89.0% by weight of water, wherein the aqueousemulsion of a soil stabilizer and dust retardant comprises: about 5.0%to about 60.0% by weight of polyacrylic acid; and polyvinyl acetate. 4.The composition of claim 4 wherein the aqueous emulsion furthercomprises about 40.0% to about 95.0% by weight of water, wherein thecomposition further comprises an emulsifier.
 5. The composition of claim3, wherein the polyacrylic acid and polyvinyl acetate comprises amixture, the mixture being chosen from the group comprising homopolymersand copolymers.
 6. The composition of claim 5, wherein the polyacrylicacid and polyvinyl acetate mixture is present in ratios from about 1:1to about 1:10,000 by mass of polyacrylic acid to polyvinyl acetate. 7.The composition of claim 5, wherein the polyacrylic acid and polyvinylacetate mixture is present in ratios from about 1:1 to about 1:10,000 bymass of polyvinyl acetate to polyacrylic acid.
 8. The composition ofclaim 5, wherein the blend of polyacrylic acid and polyvinyl acetatecopolymers includes styrene butadiene rubber.
 9. The composition ofclaim 1, wherein the water repellant comprises: about 2.5% to about30.0% by weight of polyacrylic acid and polyvinyl acetate polymer; about0.5% to about 2.5% by weight of potassium hydroxide; about 5.0% to about15.0% by weight of potassium methylsiliconate; and about 52.5% to about92.0% by weight of water; wherein the aqueous emulsion comprises: about3.75% to about 45.0% by weight of polyacrylic acid and polyvinyl acetatepolymer; and the water repellant comprises: about 0.25% to about 1.25%by weight of potassium hydroxide; about 2.5% to about 7.5% by weight ofpotassium methylsiliconate; and about 46.25% to about 93.5% by weight ofwater.
 10. The composition of claim 1, wherein the aqueousemulsion-comprises: about 1.25% to about 15.0% by weight of polyacrylicacid and polyvinyl acetate polymer; and the water repellant comprises:about 0.75% to about 3.75% by weight of potassium hydroxide; about 7.5%to about 22.5% by weight of potassium methylsiliconate; and about 58.75%to about 90.5% by weight of water.
 11. The composition of claim 1,wherein the aqueous emulsion of a soil stabilizer and dust retardantcomprises about 0.1% to about 20.0% by weight of polyacrylic acid andpolyvinyl acetate.
 12. The composition of claim 11 wherein thecomposition further comprises about 0.1% to about 40.0% by weight ofwater.
 13. A method for reducing capillary water uptake and preventingerosion, comprising the steps of: (A) providing a composition comprisinga heterogeneous mixture of an aqueous solution of a water repellant andan aqueous emulsion of a soil stabilizer and dust retardant, wherein theaqueous solution of the water repellant liquid comprises: about 0.25% toabout 5.0% by weight of potassium hydroxide; about 10.0% to about 30.0%by weight of potassium methylsiliconate; and about 65.0% to about 89.0%by weight of water; (B) applying the composition to soil or road basematerials, wherein the composition is applied at about 1 L/m³ to about100 L/m³; and, (C) allowing the composition to penetrate the soil orroad base materials.
 14. The method of claim 13, wherein the aqueousemulsion of a soil stabilizer and dust retardant comprises: about 5.0%to about 60.0% by weight of polyacrylic acid and polyvinyl acetate; and,about 40.0% to about 95.0% by weight of water.
 15. The method of claim14, wherein step (B) further comprises the steps of: scarifying the soilor road base materials before applying the composition to the soil orroad base materials; pulverizing the soil or road base material in amixing chamber using a pulvimixer; and, mixing the composition with thepulverized material.
 16. The method of claim 15, further comprisingstep: (D) grading and compacting the treated soil or road basematerials.
 17. The method of claim 16, further comprising step: (E)applying a top coat of the composition.
 18. The method of claim 13,wherein the pulvimixer has a rotor that turns at a rate of about 100 toabout 200 rpm in the opposite direction to the pulvimixer's direction oftravel, and the pulvimixer digs into the soil at a depth of up to about500 mm.